Article of footwear having an upper with a polymer layer

Abstract

A article of footwear having an upper and a sole structure secured to the upper. At least a portion of the upper includes a substrate layer and a polymer layer. The substrate layer is formed of an air-permeable material, and may be a textile or mesh material. The polymer layer defines a plurality of apertures that expose portions of the substrate layer, and the polymer layer is formed of a polymer material that infiltrates the substrate layer and is thereby secured to the substrate layer. A method of forming the material for the upper includes casting a polymer resin to form the polymer layer.

1. An article of footwear having an upper and a sole structure secured to the upper, at least a portion of the upper comprising:
 a substrate layer formed of an air-permeable textile material; and 
 a web layer defining a plurality of apertures that expose portions of the textile material of the substrate layer, the web layer being formed of a polymer material that infiltrates the textile material of the substrate layer and is thereby secured to the substrate layer, and the web layer forming an exterior surface of the upper to have a stepped configuration tat forms a plurality of ridges positioned on the exterior surface, the ridges extending between adjacent apertures. 
 
   
   
     2. The article of footwear recited in  claim 1 , wherein the textile material of the substrate layer is a non-woven. 
   
   
     3. The article of footwear recited in  claim 1 , wherein the textile material of the substrate layer is a mesh material. 
   
   
     4. The article of footwear recited in  claim 3 , wherein the mesh material includes two spaced textile layers interconnected by a plurality of connecting fibers. 
   
   
     5. The article of footwear recited in  claim 1 , wherein the web layer forms at least a portion of an exterior surface of the upper. 
   
   
     6. The article of footwear recited in  claim 5 , wherein the web layer forms at least a portion of a toe region of the upper. 
   
   
     7. The article of footwear recited in  claim 6 , wherein at least a portion of the ridges are positioned in the toe region of the footwear. 
   
   
     8. The article of footwear recited in  claim 5 , wherein the web layer forms at least a portion of a lateral region of the upper. 
   
   
     9. The article of footwear recited in  claim 8 , wherein at least a portion of the ridges are positioned in the lateral region of the footwear. 
   
   
     10. The article of footwear recited in  claim 1 , wherein the textile material is at least partially formed from a plurality of filaments or fibers, and the polymer material of the web layer extends around the plurality of filaments or fibers to secure the web layer to the substrate layer. 
   
   
     11. The article of footwear recited in  claim 1 , wherein the polymer material of the web layer is a thermoset polyurethane material. 
   
   
     12. The article of footwear recited in  claim 1 , wherein the web layer is formed through a casting process. 
   
   
     13. The article of footwear recited in  claim 12 , wherein the casting process includes placing a polymer resin into a mold such that the polymer resin infiltrates the substrate layer. 
   
   
     14. The article of footwear recited in  claim 1 , wherein the polymer material is absent from areas of the substrate layer that correspond with positions of the apertures.